Method of manufacturing carpets

ABSTRACT

A carpet is manufactured by forming a shed of warp yarns, inserting a pile yarn through the shed between layers of warp yarns defining the shed, advancing a rotating pile-wrapping rod with a hook at one end from one side of a loom across the wrap yarns to helically wrap the pile yarn around the wrapping rod so as to embrace at least one warp yarn of one layer of the warp yarns by each loop of the helix, forming the shed in the opposite direction by moving the yarns of the one layer embraced by the pile yarn loops between adjacent warp yarns of the other layer, inserting a weft through the shed, interconnecting the warp yarns with a binding weft and cutting the loops of the pile yarn along the wrapping rod.

'ialcizawa 51 Jan. 18, 1972 METHOD OF MANUFACTURING CARPETS Kinichl Takizawa, 1831-6, Gobyo-Machi, Yonezawa-shi, Japan Inventor:

Filed: Oct. 6, 1970 Appl. No.1 78,509

Related U.S. Application Data Continuation-impart of Ser. No. 668,291, Sept. 11, 1967, abandoned, Continuation-impart of Ser. No. 833,319, June 16, 1969, abandoned.

References Cited FOREIGN PATENTS OR APPLICATIONS 12/1962 U.S.S.R. ..l39/ll6.5

Primary Examiner-Henry S. Jaudon Attorney-George B. Oujevolk 57 ABSTRACT A carpet is manufactured by forming a shed of warp yarns, inserting a pile yarn through the shed between layers of warp yarns defining the shed, advancing a rotating pilewrapping rod with a hook at one end from oneside of a loom across the wrap yarns to helically wrap the pile yarn around the wrapping rod so as to embrace at least one warp yarn of one layer of the warp yarns by each loop of the helix, forming the shed in the opposite direction by moving the yarns of the one layer em braced by the pile yarn loops between adjacent warp yarns of the other layer, inserting a weft through the shed, interconnecting the warp yarns with a binding weft and cutting the loops of the pile yarn along the wrapping rod.

3 Claims, 8 Drawing Figures PATENTEDJMIIBWZ SHEET 1 0F 3 FIGZ.

Kmich: TAKJZAWA INVHNTUK.

By Georg METHOD OF MANUFACTURING CARPETS CROSS-REFERENCE TO RELATED APPLICATIONS This application is a continuation-in-part of U.S. Pat. application Ser. No. 668,291, filed Sept. 11, I967 and of Ser. No. 833,319 filed June 16, I969 both now abandoned.

BACKGROUND OF THE INVENTION This invention relates to a method of manufacturing carpets.

For many centuries carpets have been manufactured in various countries, such as Persia, China, etc., but they have been mainly manufactured by hand. Typically they are fabricated by suitably binding pile yarns to warp yarns which are arranged in parallel in two (front and rear) layers to form tufts of yarns and then bringing free ends of the tufts to the front side of the carpet. However, in the manufacture of carpets it is inevitable that waste of a considerable quantity of raw material during the in-planting and finishing steps of piles occurs. This is of course uneconomical, and of low efficiency, thus greatly increasing the manufacturing cost. It has been attempted to manufacture carpets by use of looms, but such attempts have not been successful because of the low tensile strength of pile yarns and the complicated mechanism of the looms.

SUMMARY OF THE INVENTION Thus, it is an object of this invention to provide a new and improved method of manufacturing carpets.

According to this invention there is provided a method of manufacturing a carpet comprising the steps of forming a shed of warp yarns, inserting a pile yarn through the shed between layers of warp yarns defining the shed, advancing a rotating pile-wrapping rod with a hook at one end from one side of a loom across the warp yarns to helically wrap the pile yarn around the wrapping rod, the loops of the helix each embracing at least one warp yarn of one layer of the warp yarns, forming the shed in the opposite direction by moving the warp yarns of the one layer embraced by the pile yarn loops between adjacent warp yarns of the other layer, inserting a weft through the shed, interconnecting the warp yarns with a binding weft and cutting the loops of pile yarn along the wrapping rod. These process steps are repeated to form a carpet. If desired, after cutting the loops of pile yarn one layer of warp yarns is moved transversely relative to the other layer and the shed is reformed. Then a second pile is inserted, looped and interconnected in the same manner as above described. By alternately repeating the group of steps utilizing the first pile yarn and the group of steps utilizing the second pile, a carpet of a different type can be obtained.

BRIEF DESCRIPTION OF THE DRAWINGS The invention can be more fully understood from the following description taken in connection with the accompanying drawings in which:

FIG. 1 is a sectional view of a portion of a carpet manufactured according to the method herein described so as to explain the construction thereof in which warp yarns are shown in section;

FIG. 2 is a sectional view to show a hook of a pile-wrapping rod for wrapping a pile inserted between adjacent warp yarns;

FIG. 3 shows a plan view of FIG. 2;

FIG. 4 is a sectional side view to'show the state in which pile yarns are helically wrapped around a pile-wrapping rod;

FIG. 5 is a plan view of the arrangement shown in FIG. 4;

FIG. 6 represents a longitudinal section to show the manner of severing pile yarns which are spirally wrapped;

FIG. 7 shows a transverse sectional view of FIG. 6; and,

FIG. 8 is a partial sectional view to explain the manner of inplanting pile yarns.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the accompanying drawings, a carpet fabricated in accordance with the invention comprises front warp yarns l (1,4 rear warp yarns 2 (2 -2 base wefts 3, pile yarns 5 (5 -5 and binder wefts 6. As described later in more detail, pile yarns are looped around the warp yarns as they are helically wound upon a pile-wrapping rod 8 having a hook 9 at one end for engaging the pile yarns and a longitudinal groove. The wrapping rod 8 is supported and guided by a bearing 11 and the helically wound pile yarns are severed by means of a knife 12 shown in FIGS. 6 and 7.

In order to fabricate a carpet having the construction shown in FIG. I, a shed is formed between the front and rear warp yarns 1 and 2, with the rear warp yarnsthe uppermost, as shown in FIGS. 2 and 3, pile yarns 5 under constant tension are inserted through the shed from one side of the loom by means of a rod (not shown) engaging the free ends of the yarns which are retained on the other side of the loom by a suitable clamping device (shown schematically in FIG. 3). Thereafter the wrapping hook 9 secured to one end of the pile-wrapping rod 8 is inserted into the gap between adjacent rear warp yarns 2 to engage the pile yarn 5 to form loops of the yarns 5 around each, or a predetermined number of rear warp yarns and wind the yarns 5 helically around the pile-wrapping rod 8. More particularly, the pile-wrapping rod 8 is advanced across the warp yarns l and 2 in the direction of the dotted line arrow of FIG. 3 and is simultaneously rotated about its axis whereby to helically wrap pile yarns 5 around itself as shown in FIG. 5 to form loops around the warps 2. The pilewrapping rod 8 is advanced one pitch for each of its revolutions during which the hook is inserted into the gap between adjacent rear warp yarns 2.

After forming a helix of pile yarns around the pile-wrapping rod 8 as above described, the shedding between warp yarns 1 and 2 is closed and reformed in the opposite direction for insertion of a weft 3 in conventional manner. Subsequently, a binder weft 6 is passed successively around the warp yarns l and 2 as shown in FIG. 6.

Thereafter, a heald (not shown) movable transversely relative to the yarns l and engaging only the rear warp yarns 2, is moved either to the left, as viewed in FIG. I, for in-planting pile yarns 5,-5 The knife 6 is then urged into the longitudinal slot 10 in the rod 8 to cut the loops of the yarns 5. The shedding is then closed and reformed in the opposite direction and the cycle for forming the loops of the yarns 5 recommenced.

By repeating the above-described cycle of operation, a desired carpet can be obtained.

FIG. 8 shows a case wherein the heald (not shown) has been moved to the right to in-plant the pile yarns 5.

The above-described steps are terminated when loops of the yarns 5 are cut and when the same steps are repeated, a carpet having pile yarns 5 alone is obtained as shown in FIG. 8. However, after in-planting the pile yarns 5, when one layer of the shed is moved laterally relative to the other layer, and the other pile yarns 5 are in-planted by the same process steps, a carpet of the construction shown in FIG. I, can be obtained.

It should be understood that this invention is not limited to any particular combinations of warp yarns and position of the binder wefts and base wefts, and the like.

Thus, it will be clear that according to this invention, as pile yarns are wound upon the same pile-wrapping rod of uniform diameter, with the same tension, and with the same pitch to form the loops, the tufts of the pile prepared by cutting the loops are all the same length. Further, by utilizing yarnwrapping rods of different diameters, the length of the tufts can be varied to any desired value. This not only greatly increases the operating efficiency, but also reduces the waste of raw material, thus lowering the manufacturing cost of the carpet. As the pile yarns are wound helically upon the pilewrapping rod, they are in-planted in a twisted state so that their resistance to pulling out is increased, and therefore, the

durability of the carpet by the method of this invention is warp yarns of the one layer embraced by the pile yarn greater than that made by a conventional method. loops between adjacent warp yarns of the other layer;

What is claimed is: e. inserting a weft through the shed;

1. A method of manufacturing a carpet comprising the steps f. interconnecting the warp yarns with a binding weft; and, f: 5 3. cutting said loops of pile yarn along said wrapping rod.

forming a Shed ofwarp yams; 2. The method as claimed in claim 1, wherein the one layer b. inserting a pile yarn through the shed between layers of warp yarns defining the shed;

c. advancing a rotating pilewrapping rod with a hook on one end from one side of a loom across said warp yarns to helically wrap said pile yarn around said wrapping rod, the loops of the helix each embracing at least one warp yarn of one layer of the warp yarns;

d. forming the shed in the opposite direction by moving the of the warp yarns is moved transversely relative to the other layer after the loops of pile yarns have been cut and then a second pile yarn is in-planted by the same steps as in claim 1.

3. The method as claimed in claim 1, wherein said pilewrapping rod is formed with a groove on the peripheral surface in parallel with its axis to receive a cutter. 

1. A method of manufacturing a carpet comprising the steps of: a. forming a shed of warp yarns; b. inserting a pile yarn through the shed between layers of warp yarns defining the shed; c. advancing a rotating pile-wrapping rod with a hook on one end from one side of a loom across said warp yarns to helically wrap said pile yarn around said wrapping rod, the loops of the helix each embracing at least one warp yarn of one layer of the warp yarns; d. forming the shed in the opposite direction by moving the warp yarns of the one layer embraced by the pile yarn loops between adjacent warp yarns of the other layer; e. inserting a weft through the shed; f. interconnecting the warp yarns with a binding weft; and, g. cutting said loops of pile yarn along said wrapping rod.
 2. The method as claimed in claim 1, wherein the one layer of the warp yarns is moved transversely relative to the other layer after the loops of pile yarns have been cut and then a second pile yarn is in-planted by the same steps as in claim
 1. 3. The method as claimed in claim 1, wherein said pile-wrapping rod is formed with a groove on the peripheral surface in parallel with its axis to receive a cutter. 